Ross 27 Series Installation guide

Type
Installation guide
27 Series Explosion-Proof Poppet Valves
Thank You!
You have purchased a premium-quality ROSS
®
pneumatic valve.
It is a poppet valve designed for inline mounting, and has been
built to the highest standards.
With care in its installation and maintenance, you can expect it to
have a long and economical service life. So before you go any
further, please take a few minutes to look over the information
in this folder. Then save it for future reference and for the useful
service information it contains. A general service manual with
more detailed information is available from ROSS upon request.
VALVE INSTALLATION
Pneumatic equipment should be installed only by
persons trained and experienced in such installation.
Important Note:
ROSS 27 Series valves are not designed as control
valves for air clutch/brake mechanisms on mechanical
power presses, and must not be installed for such use.
Only double valves conforming to OSHA standards
shall be used in such applications.
Air Lines: Before installing a valve in a new or an
existing system, the air lines must be blown clean of
all contaminants. It is recommended that an air filter be
installed in the inlet line close to the valve.
Valve Inlet (Port 1): Be sure that the supply line is
of adequate size and does not restrict the air supply
because of a crimp in the line, a sharp bend, or a
clogged filter element.
Valve Outlets (Ports 2 and 4): For faster pressurizing
and exhausting of the mechanism being operated by
the valve, locate the valve as close as possible to the
mechanism. The lines must be of adequate size and be
free of crimps and sharp bends.
Valve Exhausts (Port 3): Do not restrict the air flow
from the exhaust port of the valve body or pilot body
as this can adversely affect the operation of the valve.
However, to reduce exhaust noise, an efficient silencer
may be used. ROSS silencers reduce impact noise by
as much as 25 dB, and produce little back pressure.
Electrical Supply: The voltage and hertz ratings of the
valve solenoids (if any) are shown on the pilot housing.
The electrical supply must correspond to these ratings
otherwise the solenoids are subject to early failure.
The power supply must be capable of handling the
maximum power. See Valve Specifications on page 3
for information on maximum power.
Operating Pressures and Temperatures: Allowable
ranges for pressure and temperatures are given in the
Valve Specifications on page 3. Exceeding the values
shown can shorten valve life.
Pilot Supply:
Pressure for the pilot valve is supplied internally for most
valves, and requires no special connection. See Valve
Specifications, for pressure requirements.
Pipe Installation: To install pipe in valve ports,
engage pipe one turn, apply pipe thread sealant (tape
not recommended), and tighten pipe. This procedure
will prevent sealant from entering and contaminating
the valve.
IMPORTANT NOTE: Please read carefully and thoroughly all the WARNINGS and CAUTIONS on page 4.
ROSS CONTROLS
®
www.rosscontrols.com
Please read and make sure you understand all installation instructions before proceeding with the installation.
Additional technical documentation is available for download at www.rosscontrols.com.
If you have any questions about installation or servicing your valve, please contact ROSS or your authorized ROSS
distributor, see contact information listed at the back of this document, or visit www.rosscontrols.com to find your distributor.
Pneumatic equipment should be maintained only by persons
trained and experienced in the maintenance of such equipment.
Supply Clean Air. Foreign material lodging in valves is a major cause
of breakdowns. The use of a 5-micron rated air filter located close to
the valve is strongly recommended. The filter bowl should be drained
regularly, and if its location makes draining difficult, the filter should
be equipped with an automatic drain.
Check Lubricator Supply Rate. A lubricator should put a fine oil mist
into the air line in direct proportion to the rate of air flow. Excessive
lubrication can cause puddling in the valve and lead to malfunctions.
For most applications an oil flow rate in the lubricator of one drop
per minute is adequate. (Note that the double valve itself does not
require air line lubrication.)
Compatible Lubricants. Although this valve does not require air
line lubrication, it may be used with lubricated air being supplied to
other mechanisms. Some oils contain additives that can harm seals
or other valve components and so cause the valve to malfunction.
Avoid oils with phosphate additives (e.g., zinc dithiophosphate), and
diester oils; both types can harm valve components. The best oils
to use are generally petroleum base oils with oxidation inhibitors,
an aniline point between 180°F (82°C) and 220°F (104°C), and an
ISO 32 or lighter viscosity.
Some compatible oils are listed above at the right. These oils,
although believed to be compatible, could change without notice
because manufacturers sometimes reformulate their oils. Therefore,
use oils specifically compounded for air line service. If it is a synthetic
oil, contact the oil manufacturer for compatibility information.
Cleaning the Valve. If the air supplied to the valve has not been
well filtered, the interior of the valve may accumulate dirt and varnish
which can affect the valve’s performance.
This can cause sluggish or erratic valve action and nuisance
lockouts. A schedule should be established for cleaning all valves,
the frequency depending on the cleanliness of the air being supplied.
COMPATIBLE LUBRICANTS
Maker Brand Name
Amoco ...............American Industrial Oil 32
Amoco Spindle Oil C, Amolite
32
Citgo .................Pacemaker 32
Exxon ................Spinesstic 22, Teresstic 32
Mobil .................. Velocite 10
Non-Fluid Oil .....Air Lube 10H/NR
Shell ...................Turbo T32
Sun ....................Sunvis 11, Sunvis 722
Texaco ...............Regal R&O 32
Union .................Union Turbine Oil
2 ROSS CONTROLS
®
VALVE MAINTENANCE
To clean the valve use any good commercial
solvent. Do not scrape varnished surfaces. Also do
not use chlorinated solvents or abrasive materials.
The former damages seals, and abrasives can
do permanent damage to metal parts. Before
reassembling the valve, lubricate all sliding surfaces
with a grease such as MobilGrease 28.
Electrical Contacts. In the electrical circuits
associated with the valve solenoids, keep all
switches or relay contacts in good condition to avoid
solenoid malfunctions.
Replace Worn Components. In most cases it is not
necessary to remove the valve from its installation
for servicing. However, turn off the electrical power
to the valve, shut off the air supply, and exhaust the
air in the system before beginning any disassembly
operation. Service kits are listed on page 2.
You may also request a free service manual from
ROSS in the U.S.A. at 1-800-GET-ROSS.
Applicable Requirements: C22.2 No. 0-10 - General Requirements - Canadian Electrical Code, Part II; CSA C22.2 No.
25-1966 - Enclosures for use in Class II Groups E, F and G Hazardous Locations; CSA C22.2 No. 142-M1987 - Process
Control Equipment; C22.2 No. 213-M1987 - Nonincendive Electrical Equipment for Use in Class I, Division 2 Hazardous
Locations; CAN/CSA E79-0-95 - Electrical apparatus for explosive atmospheres, Part 0: General requirements; CAN/
CSA E79-18-95 - Electrical apparatus for explosive atmospheres, Part 18: Encapsulation "m".
APPROVED for use in the following Hazardous LocationsEx m II T4 and Division 1 –
Specifications in accordance to CSA certificate: Class I, Division 1, Groups A, B, C and D; Class II, Groups E, F and
G; Class III; Class I, Division 2, Groups A, B, C, D.
Specifications in accordance to FM certificate: Explosion-proof Class I, Division 1, Groups A, B, C, D, T4, Ta = 60
°C (encapsulation/explosion-proof Class I, Zone 1, AEx m II T4, Ta = 60 °C; dust-ignition-proof for Class II/III, Division
1, Groups E, F and G, T4, Ta = 60 °C); Nonincendive Class I, Division 2, Groups A, B, C, D, T4, Ta = 60 °C; Suitable for
Class II, III, Division 2, Groups E, F, G, T4, Ta = 60 °C
CSA CLASS 2258 02 – process control equipment – for hazardous locations; FM CLASS 3600, 3611, 3615, 3810 – hazardous (classified)
location electrical equipment
Explosion Protection Reference Guide
www.rosscontrols.com 3
VALVE SPECIFICATIONS
VALVE SERVICE
If you have any questions about installing or servicing your valve, call ROSS Technical Services at your nearest ROSS
location (see page 4) or in the U.S.A. at: 1-888-TEK-ROSS.
IMPORTANT NOTE: Please read carefully and thoroughly all the WARNINGS and CAUTIONS on page1 and page 4.
Construction: Poppet; Acetal.
Mounting Type: In-Line.
Solenoid Pilot: Rated for continuous duty.
Standard Voltages/Pilot Solenoids Power
Consumption (each solenoid): 24 volts DC, 4.6 watts;
120 volts AC, 60 Hz, 6.8 volt amps.
Ambient Temperature: 40° to 140°F (4° to 60°C).
Media Temperature: 40° to 175°F (4° to 80°C).
Flow Media: Filtered air.
Inlet Pressure:
Body Size 3/8, 3/4, 1
½
: 15 to 150 psig (1 to 10 bar).
Body Size 2: 30 to 150 psig (2 to 10 bar).
Valve Body Service Kits.
These kits contain all parts needed for complete
reconditioning of a valve body. Included are poppets,
spindle, all required gaskets and seals, and
instructions for use.
Order by the kit numbers listed at the right.
Gasket and Seal Kits.
These kits are needed when valve bodies are
disassembled for cleaning. They include all the
necessary gaskets, O-rings, and other seals.
Order by the kit numbers listed at the right.
Solenoid Pilot.
Replacement pilot valve can be ordered by the
following part number: 1488G79.
Specify voltage when ordering.
Solenoids.
Replacement solenoids can be ordered by the
following part number: 409B33.
Specify voltage when ordering.
Valve
Type
Port Sizes
Body
Size
Valve Body
Kit Number*
Gasket & Seal
Kit Number*
2/2
Normally
Closed
1/4, 3/8, 1/2 3/8 501K87 513K87
1/2, 3/4, 1 3/4 502K87 514K87
1, 1¼, 1½ 1¼ 503K87 515K87
1½, 2, 2½ 2 547H77
2/2
Normally
Open
1/4, 3/8, 1/2 3/8
504K87 513K87
1/2, 3/4, 1 3/4
505K87 514K87
1, 1¼, 1½ 1¼
506K87 515K87
1½, 2, 2½ 2
548H77
3/2
Normally
Closed
1/4, 3/8, 1/2 3/8
495K87 510K87
1/2, 3/4, 1 3/4
496K87 511K87
1, 1¼, 1½ 1¼
497K87 512K87
1½, 2, 2½ 2
814K77
3/2
Normally
Open
1/4, 3/8, 1/2 3/8
498K87 510K87
1/2, 3/4, 1 3/4
499K87 511K87
1, 1¼, 1½ 1¼
500K87 512K87
1½, 2, 2½ 2
550H77
4/2
1/4, 3/8, 1/2 3/8
492K87 507K87
1/2, 3/4, 1 3/4
493K87 508K87
1, 1¼, 1½ 1¼
494K87 509K87
ROSS would be happy to service this valve for you at its factory repair center. If you purchased your valve
from ROSS please contact ROSS customer service, if you purchased your valve thru an authorized ROSS
distributor please contact the distributor for return instructions.
However, if you choose to service this valve yourself, it is strongly recommended that you visit our website at
www.rosscontrols.com for available downloadable technical documentation.
Printed in the U.S.A. – Rev. 05/17 © 2017, ROSS CONTROLS
®
. All Rights Reserved. Form SS309
Content subject to change.
PRE-INSTALLATION or SERVICE
1. Before servicing a valve or other pneumatic component, be sure
that all sources of energy are turned off, the entire pneumatic system
is shut off and exhausted, and all power sources are locked out (ref:
OSHA 1910.147, EN 1037).
2. All ROSS
®
products, including service kits and parts, should
be installed and/or serviced only by persons having training and
experience with pneumatic equipment. Because any installation can be
tampered with or need servicing after installation, persons responsible
for the safety of others or the care of equipment must check every
installation on a regular basis and perform all necessary maintenance.
3. All applicable instructions should be read and complied with before
using any fluid power system in order to prevent harm to persons
or equipment. In addition, overhauled or serviced valves must be
functionally tested prior to installation and use. If you have any
questions, call your nearest ROSS location listed in the table below.
4. Each ROSS product should be used within its specification limits.
In addition, use only ROSS parts to repair ROSS products.
WARNINGS: Failure to follow these directions can adversely affect
the performance of the product or result in the potential
for human injury or damage to property.
FILTRATION and LUBRICATION
5. Dirt, scale, moisture, etc. are present in virtually every air system.
Although some valves are more tolerant of these contaminants than
others, best performance will be realized if a filter is installed to clean
the air supply, thus preventing contaminants from interfering with the
proper performance of the equipment. ROSS recommends a filter
with a 5-micron rating for normal applications.
6. All standard ROSS filters and lubricators with polycarbonate
plastic bowls are designed for compressed air applications only. Do
not fail to use the metal bowl guard, where provided, to minimize
danger from high pressure fragmentation in the event of bowl failure.
Do not expose these products to certain fluids, such as alcohol or
liquefied petroleum gas, as they can cause bowls to rupture, creating
a combustible condition, hazardous leakage, and the potential for
human injury or damage to property. Immediately replace a crazed,
cracked, or deteriorated bowl. When bowl gets dirty, replace it or
wipe it with a clean dry cloth.
7. Only use lubricants which are compatible with materials used in
the valves and other components in the system. Normally, compatible
lubricants are petroleum based oils with oxidation inhibitors, an
aniline point between 180°F (82°C) and 220°F (104°C), and an ISO
32, or lighter, viscosity. Avoid oils with phosphate type additives
which can harm polyurethane components, potentially leading to
valve failure which risks human injury, and/or damage to property.
AVOID INTAKE/EXHAUST RESTRICTION
8. Do not restrict the air flow in the supply line. To do so could reduce
the pressure of the supply air below the minimum requirements for
the valve and thereby cause erratic action.
9. Do not restrict a valve’s exhaust port as this can adversely affect
its operation. Exhaust silencers must be resistant to clogging and
must have flow capacities at least as great as the exhaust capacities
of the valves. Contamination of the silencer can result in reduced
flow and increased back pressure.
WARNINGS:
ROSS expressly disclaims all warranties and responsibility for any
unsatisfactory performance or injuries caused by the use of the
wrong type, wrong size, or an inadequately maintained silencer
installed with a ROSS product.
POWER PRESSES
10. Mechanical power presses and other potentially hazardous
machinery using a pneumatically controlled clutch and brake
mechanism must use a press control double valve with a monitoring
device. A double valve without a self-contained monitoring device
should be used only in conjunction with a control system which
assures monitoring of the valve. All double valve installations involving
hazardous applications should incorporate a monitoring system which
inhibits further operation of the valve and machine in the event of a
failure within the valve mechanism.
ENERGY ISOLATION/EMERGENCY STOP
11. Per specifications and regulations, ROSS L-O-X
®
valves
and L-O-X
®
valves with EEZ-ON
®
operation are defined as energy
isolation devices, NOT AS EMERGENCY STOP DEVICES.
STANDARD WARRANTY
All products sold by ROSS CONTROLS are warranted for a one-year period [with the exception of
all Filters, Regulators and Lubricators (“FRLs”) which are warranted for a period of seven years]
from the date of purchase to be free of defects in material and workmanship. ROSS’ obligation
under this warranty is limited to repair or replacement of the product or refund of the purchase price paid solely at the discretion of ROSS
and provided such product is returned to ROSS freight prepaid and upon examination by ROSS is found to be defective. This warranty
becomes void in the event that product has been subject to misuse, misapplication, improper maintenance, modification or tampering.
THE WARRANTY EXPRESSED ABOVE IS IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES AND ROSS EXPRESSLY DISCLAIMS
ALL OTHER WARRANTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE. ROSS MAKES NO WARRANTY WITH RESPECT TO ITS PRODUCTS MEETING THE PROVISIONS OF ANY GOVERNMENTAL
OCCUPATIONAL SAFETY AND/OR HEALTH LAWS OR REGULATIONS. IN NO EVENT IS ROSS LIABLE TO PURCHASER, USER, THEIR
EMPLOYEES OR OTHERS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES WHICH MAY RESULT FROM A BREACH OF THE WARRANTY
DESCRIBED ABOVE OR THE USE OR MISUSE OF THE PRODUCTS. NO STATEMENT OF ANY REPRESENTATIVE OR EMPLOYEE OF
ROSS MAY EXTEND THE LIABILITY OF ROSS AS SET FORTH HEREIN.
ROSS CONTROLS USA Tel: 1-248-764-1800 web site: www.rosscontrols.com
ROSS EUROPA GmbH Germany Tel: 49-6103-7597-0 web site: www.rosseuropa.com
ROSS ASIA K.K. Japan Tel: 81-42-778-7251 web site: www.rossasia.co.jp
ROSS UK Ltd. UK Tel: 44-1543-671495 web site: www.rossuk.co.uk
ROSS SOUTH AMERICA Ltda. Brazil Tel: 55-11-4335-2200 email: [email protected]
ROSS CONTROLS INDIA Pvt. Ltd. India Tel: 91-44-2624-9040 email: r[email protected]
ROSS CONTROLS (CHINA) Ltd. China Tel: 86-21-6915-7961 web site: www: rosscontrolschina.com
ROSS FRANCE S.A.S. France Tel: 33-1-49-45-65-65 web site: www.rossfrance.com
ROSS CANADA
Canada Tel: 1-416-251-7677 (416-251-ROSS) web site: www.rosscanada.com
(6077170 CANADA INC. An Independent RepResentatIve)
CAUTIONS And WARNINGS
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Ross 27 Series Installation guide

Type
Installation guide

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